Proceedings of Fatigue, Durability and Fracture Mechanics (eBook)

Dr. K. Bhanu Sankara Rao FASM, FNAE, FIIM, FASc, formerly served as Head, Mechanical Metallurgy Division at the Indira Gandhi Centre for Atomic Research, Kalpakkam. Presently he is a Ministry of Steel Chair Professor in the Mahatma Gandhi Institute of Technology, Hyderabad. He has received his B.E degree (Metallurgy) from Visvesvaraya Regional College of Engineering, Nagpur, M.Tech (Physical Metallurgy) from the Indian Institute of Technology Bombay (IIT Bombay) and Ph.D (Metallurgical Engineering) from University of Madras. His current research interests are Mechanical Metallurgy, Physical Metallurgy, Welding Science and Technology and Powder Metallurgy. He has published 250 research papers. He has been serving as an Editor of International Materials Reviews, International Review Board Member of Metallurgical and Materials Transactions and Materials Engineering and Performance since 1995. He is a member of the Technical Books Committee of ASM International. He has been the recipient of the Best Metallurgist Award from the Ministry of Steel (1995), MRSI Medal (1997), NASA Appreciation (1994), Binani Gold Medal of IIM (1990), SAIL Gold Medal (Certificate of Merit) of IIM (2000), I.T. Mirchandani (1990), H.D. Govindaraj (1990), Nucor (1996), and D&H Schechron (1994) Awards of the Indian Institute of Welding. He has served as National Research Council Fellow of USA at the NASA Lewis Research Centre, Cleveland and as a Guest Scientist at Nuclear Research Centre, Juelich, Germany and University of Siegen, Germany.Dr. S. Seetharamu received his Ph.D. in Mechanical Engineering from the Indian Institute of Science (IISc) in 1982 after obtaining his M.E. in Mechanical Engineering from IISc in 1976 and B.E. in Mechanical Engineering from Bangalore University in 1974. Dr. S. Seetharamu worked in Central Power Research Institute (CPRI) since 1985 and retired as Director in June 2015. Energy Technology and Materials Engineering are his areas of interest and special thrust is towards management of coordination with the professional working teams for collaborations, accreditations as well as custom-specific training programmes. He has worked in the Industry and has also served as a Faculty at Toyohashi University of Technology, Japan. Dr. S. Seetharamu is a leading Scientist in the Central Power Research Institute which is contributing towards the development of Electrical Industry in India. He is the recipient of several awards, holder of many patents, and a member of multiple professional bodies.Dr. Raghunath Wasudev Khare has 35+ years of experience in Finite Element Method, Materials, Metallurgy, Fatigue and Failure Assessment. He holds his Master’s and Doctorate from the Department of Mechanical Engineering, Indian Institute of Science, Bangalore. Dr. Raghunath Khare started his career with the Foundry and Forge Division of Hindustan Aeronautics Limited and later worked with various organisations as a Material & Failure Expert. He is the lead auditor for the failure investigations projects from Central Power Research Institute [CPRI] and Triveni Turbines, DHIO Research and Engineering Pvt Ltd., and so on. He has solved various industrial failure cases ranging from auto, aero and power plant companies. Dr. Raghunath Khare currently heads the Institute of Structural Integrity and Failure Studies [ISIFS],  consortium of experts with decades of experience in solving the real-time industrial – fatigue, fracture, failure problems associated with design, engineering, material, process related with insight of theoretical, analytical, experimental and computational simulation knowledge.

Preface 6
Contents 8
About the Editors 12
1 Finite Element Analysis-Based Approach for Stress Concentration Factor Calculation 14
Abstract 14
1 Introduction 14
2 Stress Concentration Factor 15
3 Methodology 16
3.1 Finite Element Analysis Based has been Used to Determine the Worst Principle Stress 16
3.2 VBA Code-Based Analytical Approach to Calculate the Stress Concentration Factor 16
3.2.1 Integration Method 16
3.2.2 Trapezoidal Method 17
Flowchart for stress concentration factor 17
4 Comparative Study 18
5 Conclusions 19
References 19
2 Evaluation of Viscoplastic Parameters of an Austenitic Stainless Steel at High Temperature 20
Abstract 20
1 Introduction 20
2 Viscoplastic Models in ANSYS 22
3 Tensile Testing of Austenitic Stainless Steel 23
4 Determination of Perzyna Parameters 25
5 Numerical Examples 26
5.1 Stress Analysis of a Tension Specimen Under Monotonic Loading 27
5.2 Cyclic Stress Analysis of a Simple Block 30
6 Calibration of Chaboche and Voce Model Parameters of SS-321 32
7 Cyclic Stress Analysis of Thrust Chamber 37
7.1 Life Cycle Prediction of Thrust Chamber 38
8 Conclusion 40
Acknowledgements 41
References 41
3 Potentiality of Small Punch Test Using Damage Model to Generate J-R Curve of 20MnMoNi55 42
Abstract 42
1 Introduction 43
2 Materials Used and Experimental Procedure 44
2.1 Materials 44
2.2 Small Punch Test Experimental Setup 44
2.3 Small Punch Test Experiment 44
2.4 Estimation and Comparison of Yield Strength and Ultimate Tensile Strength Using SPT Data 46
2.5 Calculation of Ramberg–Osgood Strain-Hardening Exponent and True Stress–Strain Data 47
3 FEA Modeling and Determination of Gurson Parameters 48
3.1 Finite Element Modeling 48
3.2 Numerical Calibration of Gurson Material Parameters 49
4 Estimation of J-R Curve Using SPT Data 50
4.1 Finite Element Modeling of CT Specimen 50
4.2 Numerical Estimation of J-R Curve 51
4.3 Numerical Modification of J-R Curves Estimation 52
5 Conclusions 52
References 52
4 Experimental Facility for Thermal Striping Studies in Dynamic Sodium Environment 54
Abstract 54
1 Introduction 55
2 Objective of the Experiments 56
3 Experimental Facility 56
4 Thermal Striping Test Vessel (TSTV) and Piping 56
5 Operation Philosophy and Process Requirements 58
6 Experimental Methodology 59
7 Experimental Scheme for TS Studies at INSOT Loop 59
7.1 Scheme for Fixing and Routing of the Thermocouples for the Instrumented Plate 59
7.2 Data Acquisition of Experimental Data 60
8 Commissioning of Thermal Striping Test Set-up (TSTS) 61
8.1 Operation of TSTS at 300 °C and Conduct of in-Sodium Trial Test 62
8.2 Conducting TS Experiments up to 550 °C 63
9 Safety Ethos Followed 63
10 Future Direction 64
11 Conclusion 64
References 64
5 Linear Elastic Fracture Mechanics (LEFM)-Based Single Lap Joint (SLJ) Mixed-Mode Analysis for Aerospace Structures 66
Abstract 66
1 Introduction 67
1.1 Scope of the Work 68
2 Approach 69
2.1 Fracture Mechanics Approach 69
2.1.1 Cohesive Zone Modeling 69
2.1.2 Bilinear Traction Separation Law 70
2.1.3 Benzeggagh and Kenane (B–K) Law 71
3 Simulation and Validation 71
3.1 Parametric Study of Cohesive Elements from Simulation of ENF and MMB Tests 72
4 Results and Discussion 73
5 Numerical Modeling of SLJ 75
6 Conclusion 77
7 Future Scope of Work 78
References 78
6 Study of Fatigue Crack Growth Rate of AA6061 at Different Stress Ratios 80
Abstract 80
1 Introduction 80
2 Experimental Details 81
3 Results and Discussion 82
3.1 Fatigue Crack Growth Data 82
3.2 Mathematical Modeling of Crack Growth Based on Walker Approach 85
4 Conclusion 86
References 86
7 Cooler Casing Fatigue Analysis: An ASME Approach 88
Abstract 88
1 Introduction 88
2 Material Selection 90
3 Design Methods 91
4 Fatigue Screening Criteria 92
5 Finite Element Analysis 95
5.1 Steady-State Thermal 96
5.2 Maximum Pressure Standard Operation 96
5.3 Fatigue Assessment 100
5.3.1 Pressure Boundary Fatigue Assessment 100
5.3.2 Non-pressure Boundary Fatigue Assessment 103
6 Conclusion 103
References 104
8 Failure Analysis of HSS Punch Tool: A Case Study 105
Abstract 105
1 Introduction 106
2 Materials and Methods 106
2.1 Materials 106
2.2 Methods 106
2.2.1 Heat Treatment Process 107
2.2.2 Cold Forging 107
2.2.3 Visual Inspection 107
2.2.4 Chemical Composition 108
2.2.5 Hardness 108
2.2.6 Microstructure 108
2.2.7 Retained Austenite 108
2.2.8 Fractography Analysis 108
3 Results and Discussion 108
3.1 Visual Inspection 108
3.2 Chemical Analysis 109
3.3 Hardness Measurement 109
3.4 Microstructure Analysis 110
3.5 Retained Austenite 110
3.6 Fractographic Studies Using Scanning Electron Microscopy 110
4 Conclusions 113
Acknowledgements 113
References 113
9 Evaluation of Fatigue Strength of Alloy Steel Pipe Under Influence of Hydrostatic Pressure 114
Abstract 114
1 Introduction 115
1.1 Fatigue 115
1.2 Hydrostatic Pressure 116
2 Experimental Details 116
2.1 Methodology 116
2.2 Finite Element Analysis of Test Specimen Pipe 117
2.3 Specimen Preparation 117
2.4 Schematic Diagram of Test Setup 118
2.5 Experimental Procedure 119
3 Result and Discussion 120
3.1 Basquin Law 120
3.2 Tensile Test 121
3.3 Plain Fatigue Test 121
3.4 Hydrostatic Fatigue Test 123
3.5 Comparison Between Plain and Hydrostatic Fatigue 123
3.6 SEM Image of Plain Fatigue Test 125
3.7 SEM Image of Hydrostatic Fatigue Test 126
4 Conclusion 127
References 127
10 Estimation of Fatigue Life of Notched Specimens of P91 Steel by Analytical Approaches 128
Abstract 128
1 Introduction 129
2 Experimental Details 130
3 Results and Discussion 131
3.1 Fatigue Behavior of Smooth Specimens 131
3.2 Fatigue Behavior of Notched Specimens 133
4 Conclusions 138
Acknowledgements 138
References 138
11 Effect of Induced Residual Stress and Its Contribution to the Failure of an IC Engine Valve Material 140
Abstract 140
1 Introduction 141
2 Failure Observations 142
2.1 Engine Observation 142
2.2 Valve Observation 142
2.2.1 Chemical Composition Analysis 142
2.2.2 Hardness Analysis 143
2.2.3 Inclusions Analysis 144
2.3 Process Observation 147
3 Stress Calculations 148
3.1 Stress Study 148
3.2 Residual Stress Measurement 148
4 Reduction of Inferring Stress 149
4.1 Stress Relieve Process 149
5 Conclusions 151
References 151
12 Fatigue Analysis of Offshore Structures in Indian Western Offshore 153
Abstract 153
1 Introduction 154
2 Fatigue in Offshore Tubular Structures 154
2.1 Fatigue Assessment 154
2.2 Analysis Methodology 158
3 Case Study 160
3.1 Results 160
4 Conclusion 161
Acknowledgements 161
References 161
13 Crack Effect on Rotors Using Mode-I Failure Model with Transfer Matrix Approach 162
Abstract 162
1 Introduction 162
2 Mathematical Modeling 164
2.1 Additional Flexibility Due to Crack 164
2.2 Transfer Matrix Method 165
2.3 Breathing Crack 167
3 Results and Discussion 168
3.1 Effect of Crack Depth 169
3.2 Effect of Crack Location 170
3.3 Modeling of Crack in 2-D 171
3.4 Fatigue Analysis of System on Difference Condition 172
4 Conclusions 172
Appendix: The Flexibility Coefficient Derivation 173
References 173
14 Multiaxial Fatigue Analysis—Approach Toward Real-World Life Prediction 175
Abstract 175
1 Introduction 176
1.1 Multiaxial Fatigue Analysis 176
1.2 Necessity 176
1.3 Terms Associated with Multiaxiality 178
1.4 Fatigue Damage Modeling 178
1.5 Mean Stress Correction 183
1.6 Multiaxial Plasticity 184
2 n-Code Multiaxial Fatigue Analysis Approach 187
3 Multiaxial Fatigue Analysis and Discussion 190
4 Conclusion 191
References 191
15 Effect of Loading Rate and Constraint on Dynamic Ductile Fracture Toughness of P91 Steel 192
Abstract 192
1 Introduction 193
2 Material 194
3 Pre-cracking of Charpy V-Notch Specimens 195
4 Experimental 195
5 Smoothening of P-d Plots 196
6 Current Crack Length Estimation Methodologies 197
6.1 Normalization Method 197
6.2 Compliance Ratio ‘CR’ Key Curve Method 198
7 Results and Discussion 200
8 Conclusions 207
References 207
16 Fatigue Life Prediction of Commercial Dental Implant Using Analytical Approach and Verification by FEA 209
Abstract 209
1 Introduction 210
2 Implant System 210
2.1 Implant Selection 210
2.2 Implant–Bone Interface 210
2.3 Interface Conditions 211
3 Materials and Methods 211
3.1 Geometrical Modeling 211
3.2 FE Modeling 212
3.3 Material Properties 212
3.4 Load and Boundary Conditions 213
3.5 Assumptions 213
4 Experimental Procedure 213
4.1 Photoelastic Test Setup 213
4.2 Photoelastic Material Model 214
4.3 Implant Fitment 214
5 Results and Discussion 214
6 Fatigue Life Predictions 215
7 Conclusion 216
References 217
17 Layered Microstructure Generated by Multipass Friction Stir Processing in AZ91 Alloy and Its Effect on Fatigue Characteristics 219
Abstract 219
1 Introduction 219
2 Experimental Method 220
3 Results and Discussion 221
3.1 Microstructure 221
3.2 Texture 222
3.3 Fatigue 223
4 Conclusions 227
References 227
18 Grain Refinement Mechanism and Its Effect on Strength and Fracture Toughness Properties of Al–Zn–Mg Alloy 229
Abstract 229
1 Introduction 230
2 Experimental Procedure 231
2.1 Aluminium Alloy Preparation 231
2.2 Friction Stir Processing (FSP) 231
2.3 Optical Microscopy (OM) 232
2.4 Electron Probe Microanalysis (EPMA) 232
2.5 Transmission Electron Microscopy (TEM) 233
2.6 Tensile Testing 233
2.7 Fracture Toughness (KIC) Testing 233
2.8 Scanning Electron Microscopy (SEM) 235
3 Results and Discussion 235
4 Conclusions 239
Acknowledgements 240
Appendix 240
References 241
19 Evolution of Tertiary Carbides and Its Influence on Wear Behavior, Surface Roughness and Fatigue Limit of Die Steels 243
Abstract 243
1 Introduction 243
2 Experimental Methods 244
2.1 Material Heat Treatment 244
2.2 Characterization 245
2.3 Wear Testing 246
3 Results and Discussion 246
3.1 Mechanism of Carbide Evolution 246
3.2 Carbide Density and Hardness 248
3.3 Microstructural Impact on Surface Roughness 248
3.4 Wear Behavior 249
4 Fatigue Specimen 252
4.1 Fatigue Test 253
4.2 Effect of Roughness on Crack Nucleation 253
4.3 Fatigue Mechanism 254
5 Conclusion 257
Acknowledgements 257
References 257
20 Lakshya: Life Assessment, Extension and Certification 259
Abstract 259
1 Introduction 259
2 Structural Design and Operational Life Assessment 260
2.1 Structural Design 260
2.2 Effects of Operations and Environment on Life of Lakshya 261
2.3 Effect on Life of Lakshya 262
3 Service Life Extension Criteria 262
4 Economy of Life Extension 262
5 Service Life Extension Procedure 263
5.1 Stiffness and Integrity/Health Monitoring of Airframe [4] 264
5.2 NDT of Critical Components 266
5.3 Corrective/Preventive Actions and Operational Readiness 268
6 Corrosion Due to Sea Water Ingress and Storage 268
6.1 Detection, Prevention and Repair 268
6.2 Some Design Lessons Learnt from Sea Dunking of Lakshya are as Follows [3] 269
7 Certification 271
8 Conclusion 271
Acknowledgements 272
References 272
21 Creep–Fatigue Damage Evaluation of 2.25Cr-1Mo Steel in Process Reactor Using ASME-NH Code Methodology 273
Abstract 273
1 Introduction 274
2 Creep–Fatigue Evaluation of a Process Reactor Outlet Nozzle 276
2.1 Main Design Features 276
2.2 Finite Element Analysis 278
2.3 ASME-NH Elastic Analysis of 2.25Cr-1Mo Process Reactor Outlet Nozzle 279
3 Results and Discussion 280
3.1 Fatigue Damage 280
3.2 Creep Damage and Combined Creep–Fatigue Damage 281
3.3 Effect of Hold Time, Hold Temperature and Rate of Temperature Change on Creep–Fatigue Damage 282
4 Conclusions 285
Appendix: Flowchart for Creep and Fatigue Damage Evaluation 286
References 286
22 Analysis and Design Optimization for Improved Fatigue Life of One-Way Clutch Drive Used in Starter Motor 288
Abstract 288
1 Introduction 289
2 Design Methodologies 290
3 One-Way Clutch Analysis Procedure 294
4 Initial Design Analysis and Results 297
5 Fatigue Calculations 298
6 Optimization Results 299
7 Conclusion 302
Acknowledgements 303
References 303
23 Creep–Fatigue Assessment for Interaction Between IHX Seal Holder and Inner Vessel Stand Pipe in a Pool-Type Fast Reactor as Per RCC-MR 304
Abstract 304
1 Introduction 304
2 Structural Analysis 305
3 Evaluation of Damage 309
4 Conclusion 310
References 311
24 Probabilistic Fatigue Life Estimation of Plate with Multiple Stress Concentration Zones 312
Abstract 312
1 Introduction 313
2 Deterministic Fatigue Life Estimation 314
2.1 Stress-Life Approach 314
2.2 Plate with Single Stress Concentration Zone 316
2.3 Plate with Multiple Stress Concentration Zones 318
3 Probabilistic Fatigue Life Estimation Using Latin Hypercube Sampling 320
3.1 Probabilistic Approach 320
3.2 Nastran Integration with MATLAB 321
3.3 Parametric Studies 323
4 Conclusions 326
Acknowledgements 326
References 326
25 Creep–Fatigue Interaction Study on Gas Turbine Engine Alloy 328
Abstract 328
1 Introduction 329
2 Material and Experimental Procedure 330
3 Results and Discussion 332
3.1 Tensile Testing 332
3.2 LCF and CF Tests 333
3.3 SEM Analysis 335
4 Conclusions 337
Acknowledgements 337
References 338
26 Evaluation of Implicit Reliability Level Associated with Fatigue Design Criteria of Nuclear Class-1 Piping 339
Abstract 339
1 Introduction 340
2 ASME Fatigue Design Criteria 341
3 Fatigue Curve of ASME and ANL 343
4 Parameters Affecting Fatigue Life of Components 345
4.1 Parameters Affecting Fatigue Life in Air Environment 345
4.2 Parameters Affecting Fatigue Life in Water Environment 345
4.3 Parameters Affecting Fatigue Damage Assessment 346
5 Formulation for Implicit Reliability Level in Fatigue Design 347
5.1 Fatigue Design Limit State Function 348
5.2 Stochastic Characteristics of Variables 349
5.3 Computational Procedure 350
6 Computation of Implicit Reliability Levels 351
6.1 Sensitivity Analysis 351
6.2 Failure Probability Evaluation 351
7 Conclusion 353
References 354
27 The Tensile Fatigue Behaviour of Aligned MWNT/Epoxy Nanocomposites 355
Abstract 355
1 Introduction 356
2 Experimental 357
2.1 Materials 357
2.2 Specimen Preparation 357
2.3 Testing Procedure 359
3 Results and Discussion 360
4 Conclusions 362
Acknowledgements 362
References 362
28 Thermo-Mechanical Creep and Recovery of CTBN–Epoxy Shape Memory Polymers Under Saline Environment 364
Abstract 364
1 Introduction 364
2 Experimental 365
2.1 Material and Specimen Preparation 365
2.2 Creep Tests 366
2.3 Salt Spray Test 366
3 Results and Discussions 367
3.1 Influence of Temperatures and Loads 367
3.2 Influence of CTBN and Saline Environment 367
4 Conclusions 370
References 370
29 Fatigue Life Estimation of Components Mounted on PCB Due to Vibration 372
Abstract 372
1 Introduction 373
2 Literature Review 373
3 Vibration Analysis of a PCB Mounted with Transistors 375
3.1 Modal Analysis of PCB with Four Transistors 375
3.2 Stress Analysis of PCB with Four Transistors 375
3.3 Fatigue Life Calculation for the Component Pin 377
4 Vibration Analysis of Transistor Alone 378
4.1 Frequency Response Analysis of Transistor 378
4.2 Fatigue Life Calculation for the Component Pin Due to Sine Vibration 379
4.3 Fatigue Life Calculation for the Component Pin Due to Random Vibration 380
5 Conclusions 381
Acknowledgements 382
References 382
30 Modified Rainflow Counting Algorithm for Fatigue Life Calculation 383
Abstract 383
1 Introduction 383
2 Concept of Rainflow Counting Method 384
3 Computer Programming of MGRM 386
4 Illustrative Example 387
5 Conclusion 389
References 389
31 Damage Prognosis of Plain Concrete Under Low-Cycle Fatigue Using Piezo-Based Concrete Vibration Sensors 390
Abstract 390
1 Introduction 391
2 High-Stress Low-Cycle Compressive Fatigue 393
2.1 Experimental Program 393
2.2 Data Analysis and Results 393
3 Conclusions 396
References 397
32 Asymmetric Cyclic Behaviour of Fine- and Coarse-Grained Commercially Pure Copper and Aluminium 398
Abstract 398
1 Introduction 398
2 Experimental Procedure 400
3 Results and Discussion 403
3.1 Microstructure and Tensile Properties 403
3.2 Ratcheting Deformation Behaviour 404
3.3 Ratcheting Strain Rate Evolution 407
3.4 Fractography 409
4 Conclusions 411
Acknowledgements 411
References 411
33 High-Temperature Fatigue Crack Growth Behaviour of SS 316LN 413
Abstract 413
1 Introduction 413
2 Experimental 415
3 Results and Discussion 415
3.1 FCG Results 415
3.2 Effect of Crack Closure and Dynamic Strain Ageing (DSA) on FCG 417
3.3 Effect of Modulus (E) and Yield Strength ( /sigma_{y} ) on FCG 418
4 Conclusions 421
Acknowledgements 421
References 421
34 Numerical Simulation of Fracture in Coatings Subjected to Sudden Temperature Change Using Element-Free Galerkin Method 423
Abstract 423
1 Introduction 423
2 Derivation of EFGM Shape Functions 424
3 Jump Function Approach for Interface Modeling 425
4 Computation of SIFs by Employing Interaction Integral Scheme 426
5 Numerical Execution 427
5.1 Edge Crack Under Thermal Load 429
6 Conclusion 430
References 430
35 Measurement of Residual Stress Distribution and Fatigue Life Assessment of Similar and Dissimilar Butt-Welded Joint 432
Abstract 432
1 Introduction 432
2 Experimental Details 434
3 Results and Discussions 437
3.1 Effect of Shot Peening on Residual Stress 437
3.2 Effect of Shot Peening on Fatigue Life 438
3.3 Effect of Shot Peening on Hardness 439
4 Conclusions 442
References 442
36 Fatigue Life Prediction of Spot Welded Joints: A Review 443
Abstract 443
1 Introduction 443
2 Models for Fatigue Life Assessment 445
3 Design and Process Parameters 447
3.1 Specimen Thickness and Nugget Diameter 447
3.2 Effect of Material Strength 449
3.3 Effects of the Loads 449
3.4 Distance Between Two Spot 450
3.5 Effect of Corrosive Field 451
3.6 Numerical Modeling 451
4 Conclusion 452
References 453
37 Crystal Orientation Effect on SIF in Single Crystals: A Study Based on Coupled Framework of XFEM and Crystal Plasticity Model 454
Abstract 454
1 Introduction 454
2 Crystal Plasticity Based Material Modeling 455
2.1 Kinematics 456
2.2 Constitutive Laws 457
2.3 Hardening Law 458
3 Extended Finite Element Method (XFEM) 459
4 Numerical Modeling 460
5 Results and Discussion 462
5.1 Effect of Lattice Orientation on Deformation Behavior of Single Crystal 462
5.2 Effect of Crystal Orientation on Mode I Stress Intensity Factor /left( {K_{I} } /right) 464
6 Conclusions 467
References 467